US9071907B2 - Vacuum insulated structure tubular cabinet construction - Google Patents

Vacuum insulated structure tubular cabinet construction Download PDF

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Publication number
US9071907B2
US9071907B2 US13/836,143 US201313836143A US9071907B2 US 9071907 B2 US9071907 B2 US 9071907B2 US 201313836143 A US201313836143 A US 201313836143A US 9071907 B2 US9071907 B2 US 9071907B2
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US
United States
Prior art keywords
tube
forming
vacuum
side walls
refrigerator housing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
US13/836,143
Other versions
US20130256318A1 (en
Inventor
Steven J. Kuehl
Axel Julio Ramm
Guolian Wu
James W. Kendall
Nihat Cur
Paul B. Allard
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Whirlpool Corp
Original Assignee
Whirlpool Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to US13/835,449 priority Critical patent/US8944541B2/en
Priority claimed from US13/833,685 external-priority patent/US9221210B2/en
Priority to US13/837,659 priority patent/US8986483B2/en
Priority to US13/836,143 priority patent/US9071907B2/en
Priority to US13/833,696 priority patent/US9038403B2/en
Priority to US13/836,669 priority patent/US9140481B2/en
Priority to US13/832,246 priority patent/US9182158B2/en
Application filed by Whirlpool Corp filed Critical Whirlpool Corp
Priority claimed from US13/833,635 external-priority patent/US20130257257A1/en
Priority claimed from US13/832,246 external-priority patent/US9182158B2/en
Assigned to WHIRLPOOL CORPORATION reassignment WHIRLPOOL CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ALLARD, PAUL, KENDALL, JAMES, KUEHL, STEVEN, RAMM, AXEL JULIO, WU, GUOLIAN, CUR, NIHAT
Publication of US20130256318A1 publication Critical patent/US20130256318A1/en
Priority to EP14158608.1A priority patent/EP2778580B1/en
Priority to BR102014005924-5A priority patent/BR102014005924B1/en
Priority to US14/635,313 priority patent/US9874394B2/en
Priority to US14/635,109 priority patent/US9885516B2/en
Priority to US14/731,796 priority patent/US9835369B2/en
Publication of US9071907B2 publication Critical patent/US9071907B2/en
Application granted granted Critical
Priority to US15/794,785 priority patent/US10663217B2/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25DREFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D23/00General constructional features
    • F25D23/06Walls
    • F25D23/065Details
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/26Making specific metal objects by operations not covered by a single other subclass or a group in this subclass heat exchangers or the like
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25BREFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B39/00Evaporators; Condensers
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25BREFRIGERATION MACHINES, PLANTS OR SYSTEMS; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS
    • F25B39/00Evaporators; Condensers
    • F25B39/02Evaporators
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25CPRODUCING, WORKING OR HANDLING ICE
    • F25C1/00Producing ice
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25DREFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D11/00Self-contained movable devices, e.g. domestic refrigerators
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25DREFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D23/00General constructional features
    • F25D23/02Doors; Covers
    • F25D23/028Details
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25DREFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D23/00General constructional features
    • F25D23/06Walls
    • F25D23/062Walls defining a cabinet
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25DREFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D23/00General constructional features
    • F25D23/06Walls
    • F25D23/062Walls defining a cabinet
    • F25D23/063Walls defining a cabinet formed by an assembly of panels
    • HELECTRICITY
    • H04ELECTRIC COMMUNICATION TECHNIQUE
    • H04RLOUDSPEAKERS, MICROPHONES, GRAMOPHONE PICK-UPS OR LIKE ACOUSTIC ELECTROMECHANICAL TRANSDUCERS; DEAF-AID SETS; PUBLIC ADDRESS SYSTEMS
    • H04R3/00Circuits for transducers, loudspeakers or microphones
    • H04R3/12Circuits for transducers, loudspeakers or microphones for distributing signals to two or more loudspeakers
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25DREFRIGERATORS; COLD ROOMS; ICE-BOXES; COOLING OR FREEZING APPARATUS NOT OTHERWISE PROVIDED FOR
    • F25D2201/00Insulation
    • F25D2201/10Insulation with respect to heat
    • F25D2201/14Insulation with respect to heat using subatmospheric pressure
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10Methods of surface bonding and/or assembly therefor
    • Y10T156/1002Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1051Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina by folding
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49002Electrical device making
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/4935Heat exchanger or boiler making
    • Y10T29/49359Cooling apparatus making, e.g., air conditioner, refrigerator
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49616Structural member making
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49826Assembling or joining
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49826Assembling or joining
    • Y10T29/49879Spaced wall tube or receptacle
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49826Assembling or joining
    • Y10T29/49947Assembling or joining by applying separate fastener
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/23Sheet including cover or casing
    • Y10T428/231Filled with gas other than air; or under vacuum

Definitions

  • Known refrigerator cabinet structures may include inner and outer walls with urethane foam or other insulating material disposed between the inner and outer walls.
  • One aspect of the present invention is a method of fabricating a vacuum insulated refrigerator housing.
  • the method includes forming an elongated tube having opposite open ends defining a link therebetween.
  • the tube may be formed from a metal material, or the tube may comprise multiple layers of polymer material, wherein one of the layers is substantially impermeable to gasses such as nitrogen, oxygen and water vapor.
  • the elongated tube has a substantially uniform cross-sectional shape along the length of the tube, and the tube defines generally planar first and second oppositely facing primary outer surfaces.
  • the tube further includes first and second end surfaces extending between the first and second primary outer surfaces.
  • the method further includes forming the tube along at least four fold lines to form at least four corners, whereby portions of the first primary surface adjacent each corner are substantially orthogonal relative to one another.
  • the method further includes sealing the opposite ends of the elongated tube to form an air-tight insulating space within the tube.
  • the opposite ends of the tubes are connected to one another to form a refrigerator housing structure that is generally “O” shaped with horizontally spaced apart, generally vertical side walls and vertically spaced apart generally horizontal upper and lower side walls forming four corners.
  • the refrigerator housing structure defines an internal space having enlarged front and rear openings.
  • the method further includes forming a vacuum in the insulating space within the tube, and attaching an insulated rear panel to the refrigerator housing structure to at least partially close off the enlarged rear opening.
  • Another aspect of the present invention is a method of forming a vacuum insulated refrigerator housing structure.
  • the method includes forming an elongated tube having opposite ends. The opposite ends are sealed to form an air-tight insulating space within the tube.
  • the method further includes forming a vacuum in the air-tight insulating space, and positioning the opposite ends of the tube adjacent to one another by deforming the tube.
  • the opposite ends are connected together to form a refrigerator housing structure that is generally “O” shaped with spaced apart upright side walls, and spaced apart upper and lower side walls extending between the upright side walls.
  • the refrigerator housing structure defines an internal space and enlarged front and rear openings.
  • FIG. 1 Another aspect of the present invention is a vacuum insulated refrigerator housing structure including a pair of horizontally spaced apart upright side walls defining upper and lower end portions.
  • the vacuum insulated refrigerator housing structure also includes an upper side wall having opposite ends connected to the upper end portions of the upright side walls, and a lower side wall having opposite ends connected to the lower end portions of the upright side walls.
  • the upright side walls and the upper and lower side walls comprise a one-piece integral tubular structure forming air-tight insulating space within the upright side walls and the upper and lower side walls.
  • the air-tight insulating space is evacuated and thus forms a vacuum insulated structure.
  • FIG. 1 is an isometric view of a refrigerator having a vacuum insulated tubular cabinet according to one aspect of the present invention
  • FIG. 2 is an exploded isometric view of the refrigerator of FIG. 1 ;
  • FIG. 3 is a cross-sectional view of the refrigerator housing of FIG. 2 taken along the line III-III;
  • FIG. 4 is a partially schematic isometric view of an extrusion apparatus and process
  • FIG. 5 is an isometric view of a tube prior to bending
  • FIG. 6 is a partially fragmentary isometric view of a portion of the tube of FIG. 5 ;
  • FIG. 7 is a partially fragmentary isometric view of a portion of the tube of FIG. 5 ;
  • FIG. 8 is a partially schematic view showing the tube of FIG. 5 during the bending process
  • FIG. 9 is a partially schematic view showing the tube of FIG. 5 during a second step of the bending process.
  • FIG. 10 is a partially fragmentary enlarged view of a portion of the tubular cabinet structure of FIG. 9 .
  • the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1 .
  • the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary.
  • the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
  • a refrigerator 1 includes an insulated cabinet structure 2 including generally upright side walls 4 A and 4 B, a horizontally extending upper side wall 6 , and a generally horizontal lower side wall 8 .
  • Doors 10 A and 10 B are moveably connected to the insulated cabinet structure 2 to provide access to an insulated interior space 14 (see also FIG. 2 ) of the refrigerator 1 .
  • the refrigerator 1 is generally configured to be supported free-standing on a floor surface 12 .
  • the insulated cabinet structure 2 includes a tubular primary structure 16 forming upright side walls 4 A and 4 B, upper side wall 6 , and lower side wall 8 .
  • the tubular primary structure 16 is generally O-shaped, with a rectangular outer perimeter 18 , and a rectangular inner perimeter 20 .
  • the inner perimeter 20 defines an enlarged rectangular front opening 22 and a rectangular rear opening 24 .
  • the rear opening 24 is closed off by a rear wall assembly 26 .
  • the rear wall assembly 26 includes an upright panel 28 , and a mullion cooling system 30 .
  • the rear wall assembly 26 may optionally include an insulated vertical panel or divider 32 that divides the insulated interior space 14 into a first space 14 A and a second space 14 B.
  • the first space 14 A may comprise a freezer space, and the space 14 B may comprise a fresh food compartment.
  • the mullion cooling system 30 may include an interior volume (not specifically shown in FIG. 2 ) that is configured to receive mechanical equipment for operating the various functions of the refrigerator 1 .
  • a cooling module set can be disposed within the interior volume of the mullion 30 . Examples of various cooling modules are disclosed in U.S. patent application Ser. No. 13/108,226 entitled “COOLING SYSTEM INTEGRATION ENABLED PLATFORM ARCHITECTURE” filed on May 15, 2011; U.S. patent application Ser. No.
  • the tubular primary structure 16 is made from an elongated tube 44 ( FIG. 5 ) that includes generally planar side walls 34 and 36 ( FIG. 3 ), and edge or end walls 30 and 40 extending transversely between the inner and outer walls 36 .
  • the tubular primary structure 16 ( FIG. 2 ) is made from a single elongated tube 44 that is deformed to form upper corners 46 A and 46 B, and lower corners 48 A and 48 B. Ends 50 A and 50 B of the tube are interconnected along an air-tight seam 52 that is preferably located in lower side wall 8 .
  • the tubular primary structure 16 includes a continuous, sealed insulating space 42 that is preferably filled with a porous filler material 54 .
  • the filler material 54 may comprise a silica powder such as fumed silica or other suitable material, and a vacuum may be formed in space 42 utilizing one or more inlet valves 56 , and one or more outlet valves 58 . Filler material 54 prevents collapse of tube 44 due to the vacuum formed in space 42 and provides superior insulation performance under vacuum.
  • tube 44 is initially formed utilizing an extrusion process.
  • An extruding apparatus 60 extrudes the tube 44 in the direction of the arrow “A”.
  • the extruding apparatus 60 may comprise a suitable known device.
  • the tube 44 may be formed from a metal material such as low carbon steel, stainless steel, aluminum, or other suitable metal.
  • tube 44 may comprise a thermoplastic polymer material such as high impact polystyrene that is co-extruded with a layer of impermeable polymer material such as ethylene vinyl alcohol (EVOH).
  • EVOH ethylene vinyl alcohol
  • the EVOH layer is substantially impermeable to oxygen, nitrogen and water vapor to thereby enable formation and maintenance of a vacuum in internal space 42 when the tube 44 is formed into the tubular primary structure 16 (see also FIG. 2 ).
  • a cutting device or apparatus 62 having a cutter 64 is utilized to cut the elongated tube 44 along a plane 66 to thereby form a tube 44 ( FIG. 5 ) having opposite ends 50 A and 50 B defining a length “L”.
  • the tube 44 is bent along the fold lines 68 A- 68 D to form corners 46 A, 46 B, 48 A and 48 B of the tubular primary structure 16 ( FIG. 2 ).
  • the side walls 38 and 40 are first deformed inwardly at each fold line 68 A- 68 D to form indentations 70 and 72 .
  • tube 44 comprises a metal material
  • the indentations 70 and 72 may be formed utilizing dies or other known metal forming tools (not shown). If the tube 44 comprises a polymer material, the indentations 70 and 72 may be formed by first heating the elongated tube 44 to soften the polymer material, and a forming tool (not shown) may be utilized to push in the side walls 38 and 40 to form the indentations 70 and 72 .
  • elongated grooves or indentations 74 and 76 may also be formed in one or both of side walls 34 and 36 at each fold line 68 A- 68 D.
  • the grooves 74 and 76 may be formed in addition to the indentations 70 and 72 , or the grooves 74 and 76 may be formed in a tube 44 that does not include indentations 70 and 72 .
  • the grooves 74 and 76 include angled side walls 78 A and 78 B that intersect at a line or crease 80 .
  • the grooves 74 and/or 76 may be formed by heating the tube 44 if the tube 44 is formed of a polymer material, followed by pressing a forming tool (not shown) into the side wall 34 and/or 36 of tube 44 . If tube 44 is made of a metal material, a conventional forming die or the like (not shown) may be utilized to form the grooves 74 and 76 .
  • the tube 44 is bent utilizing forming tools 82 A- 82 D to form corners 46 A, 46 B, 48 A and 48 B as shown in FIGS. 8-9 .
  • the ends 50 A and 50 B are then joined together at seam 52 .
  • Seam 52 may comprise a welded joint or other suitable air-tight joint that is capable of maintaining a vacuum in the interior space 42 of the tubular primary structure 16 .
  • the tube 44 Prior to bending the tube as shown in FIGS. 8-9 , the tube 44 may be filled with powdered silica such as fumed silica or other filler material.
  • the filler material 54 is inserted and compacted into the interior space 42 of tube 44 through one or both open ends 50 A or 50 B.
  • the filler material 54 may be inserted into the interior space 42 utilizing valves/openings 56 and 58 ( FIG. 2 ) after the tube 44 is deformed ( FIGS. 8-9 ), and ends 50 A and 50 B are interconnected at seam 52 .
  • forming tools 82 A and 82 B are positioned along fold lines 68 A and 68 D, and a force is applied to the tube 44 adjacent to the end portions 50 A and 50 B to thereby fold the tube 44 as shown by the arrows “F1” and “F2”. Folding of the tube 44 forms end portions 84 A and 84 B, and corners 46 A and 46 B, respectively. Sand or other temporary filler material may be positioned inside tube 44 at fold lines 68 A and 68 D to assist in the bending process.
  • forming tools 82 C and 82 D are then positioned adjacent the forming lines or location 68 B and 68 C ( FIG. 5 ), and a force is applied to a tube 44 to thereby deform the tube as shown by the arrows “F3” and “F4”.
  • the ends 50 A and 50 B of tube 44 are then welded or otherwise secured together to form an air-tight seam 52 .
  • the tubular primary structure 16 includes enlarged front and rear openings 22 and 24 .
  • the openings 22 and 24 generally define a rectangular perimeter 20
  • the tubular primary structure 16 has a generally rectangular perimeter 18 in an elevational view (e.g. FIG. 9 ).
  • the tubular primary structure 16 includes a generally rectangular “picture frame” front surface 86 A and a rectangular rear surface 86 B that is a mirror image of surface 86 A.
  • the upright rear panel 28 is disposed adjacent or against rear surface 86 A, and doors 10 A and 10 B are disposed against or adjacent surface 86 A when the doors 10 A and 10 B are in the closed position.
  • the side walls of tube 44 generally deform as shown in FIG. 10 to form a crease 80 in inner wall 34 such that the surfaces 78 A and 78 B are directly adjacent one another, or in contact one another.
  • the side walls 38 and 40 remain relatively flat in the region of the corners 46 A, 46 B, 38 A and 38 B. It will be understood that additional forming steps may be conducted in the vicinity of the corners to ensure that the outer surfaces of walls 38 and 40 are substantially planar.
  • valves/openings 56 and 58 can be utilized to remove air from cavity 42 to form a vacuum.
  • the filler material 54 may be inserted and compacted into the space 42 of tube 44 prior to formation of seam 52 .
  • the tube 44 may be formed as shown in FIGS. 4-9 , and the filler material 54 may then be inserted into space 42 utilizing valves/openings 56 and 58 .
  • the primary structure 16 can be positioned in a vacuum chamber (not shown) after formation of seam 52 , and one or both of the valves 56 and/or 58 can be opened to thereby form a vacuum in the inner space 42 .
  • the valves 56 and 58 can then be closed, and the tubular primary structure 16 can then be removed from the vacuum chamber.
  • the filler material 54 is inserted into the tube 44 prior to formation of seam 52 , the filler material 54 is preferably compacted prior to the bending process shown in FIGS. 8 and 9 .
  • the filler material 54 may be inserted and compacted by closing off an end 50 A ( FIG.
  • tube 44 utilizing a permeable barrier or filter (not shown) that permits airflow, but prevents flow of the filler material 54 .
  • the filler material 54 can then be blown into the open end 50 B. Air can be circulated along the length of the tube 44 to thereby compact and distribute the filler material 54 throughout the interior space 42 .
  • the filler material 54 may also be added after the tube 44 is bent into an O-shape (e.g. FIGS. 8 and 9 ) and after the seam 52 is formed.
  • the valves or openings 56 and 58 can be utilized to fill the space 42 with the filler material 54 .
  • a permeable barrier or filter may be positioned over opening 58 , and filler material 54 may be blown into the space 42 utilizing valve or opening 56 .
  • the airflow through the space 42 compacts the filler material.
  • the tubular structure 16 may then be placed in a vacuum chamber, and the valves or openings 56 and/or 58 may be utilized to form a vacuum in the space 42 as discussed above.
  • the filler material 54 may comprise silica powder such as fumed silica or other porous material.
  • the filler material 54 counteracts the inward forces acting on tube 44 due to the vacuum in space 42 and thereby prevents collapse or deformation of the side walls 34 , 36 , 38 and 40 of tubular structure 16 .

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • General Engineering & Computer Science (AREA)
  • Thermal Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Otolaryngology (AREA)
  • Acoustics & Sound (AREA)
  • Signal Processing (AREA)
  • Refrigerator Housings (AREA)
  • Thermal Insulation (AREA)

Abstract

A refrigerator includes a vacuum insulated cabinet structure having side walls that are formed from a tube that has been folded/deformed into a structure having an “O” shape with vertically enlarged front and rear openings. The interior of the tube may be filled with silica powder or other filler, and a vacuum is formed within the tube. An insulated rear panel may be utilized to close off the rear opening of the vacuum insulated cabinet structure.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is related to U.S. patent application Ser. No. 13/833,635 filed Mar. 15, 2013, entitled A METHOD TO CREATE VACUUM INSULATED CABINETS FOR REFRIGERATORS; and U.S. patent application Ser. No. 13/836,669 filed Mar. 15, 2013, entitled FOLDED VACUUM INSULATED STRUCTURE; and U.S. patent application Ser. No. 13/835,449 filed Mar. 15, 2013, entitled A VACUUM PANEL CABINET STRUCTURE FOR A REFRIGERATOR; and U.S. patent application Ser. No. 13/832,246 filed Mar. 15, 2013, entitled DUAL COOLING SYSTEMS TO MINIMIZE OFF-CYCLE MIGRATION LOSS IN REFRIGERATORS WITH A VACUUM INSULATED STRUCTURE; and U.S. patent application Ser. No. 13/833,696 filed Mar. 15, 2013, entitled VACUUM INSULATED DOOR STRUCTURE AND METHOD FOR THE CREATION THEREOF; and U.S. patent application Ser. No. 13/836,143 filed Mar. 15, 2015, entitled VACUUM INSULATED STRUCTURE TUBULAR CABINET CONSTRUCTION; and U.S. patent application Ser. No. 13/837,659 filed Mar. 15, 2013, entitled FOLDED VACUUM INSULATED STRUCTURE; and U.S. patent application Ser. No. 13/833,685 filed Mar. 15, 2013, entitled METHOD TO CREATE VACUUM INSULATED CABINETS FOR REFRIGERATORS, all of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
Various types of insulated cabinet structures have been developed for refrigerators, freezers and the like. Known refrigerator cabinet structures may include inner and outer walls with urethane foam or other insulating material disposed between the inner and outer walls.
SUMMARY OF THE INVENTION
One aspect of the present invention is a method of fabricating a vacuum insulated refrigerator housing. The method includes forming an elongated tube having opposite open ends defining a link therebetween. The tube may be formed from a metal material, or the tube may comprise multiple layers of polymer material, wherein one of the layers is substantially impermeable to gasses such as nitrogen, oxygen and water vapor. The elongated tube has a substantially uniform cross-sectional shape along the length of the tube, and the tube defines generally planar first and second oppositely facing primary outer surfaces. The tube further includes first and second end surfaces extending between the first and second primary outer surfaces. The method further includes forming the tube along at least four fold lines to form at least four corners, whereby portions of the first primary surface adjacent each corner are substantially orthogonal relative to one another. The method further includes sealing the opposite ends of the elongated tube to form an air-tight insulating space within the tube. The opposite ends of the tubes are connected to one another to form a refrigerator housing structure that is generally “O” shaped with horizontally spaced apart, generally vertical side walls and vertically spaced apart generally horizontal upper and lower side walls forming four corners. The refrigerator housing structure defines an internal space having enlarged front and rear openings. The method further includes forming a vacuum in the insulating space within the tube, and attaching an insulated rear panel to the refrigerator housing structure to at least partially close off the enlarged rear opening.
Another aspect of the present invention is a method of forming a vacuum insulated refrigerator housing structure. The method includes forming an elongated tube having opposite ends. The opposite ends are sealed to form an air-tight insulating space within the tube. The method further includes forming a vacuum in the air-tight insulating space, and positioning the opposite ends of the tube adjacent to one another by deforming the tube. The opposite ends are connected together to form a refrigerator housing structure that is generally “O” shaped with spaced apart upright side walls, and spaced apart upper and lower side walls extending between the upright side walls. The refrigerator housing structure defines an internal space and enlarged front and rear openings.
Another aspect of the present invention is a vacuum insulated refrigerator housing structure including a pair of horizontally spaced apart upright side walls defining upper and lower end portions. The vacuum insulated refrigerator housing structure also includes an upper side wall having opposite ends connected to the upper end portions of the upright side walls, and a lower side wall having opposite ends connected to the lower end portions of the upright side walls. The upright side walls and the upper and lower side walls comprise a one-piece integral tubular structure forming air-tight insulating space within the upright side walls and the upper and lower side walls. The air-tight insulating space is evacuated and thus forms a vacuum insulated structure.
These and other features, advantages, and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims, and appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a refrigerator having a vacuum insulated tubular cabinet according to one aspect of the present invention;
FIG. 2 is an exploded isometric view of the refrigerator of FIG. 1;
FIG. 3 is a cross-sectional view of the refrigerator housing of FIG. 2 taken along the line III-III;
FIG. 4 is a partially schematic isometric view of an extrusion apparatus and process;
FIG. 5 is an isometric view of a tube prior to bending;
FIG. 6 is a partially fragmentary isometric view of a portion of the tube of FIG. 5;
FIG. 7 is a partially fragmentary isometric view of a portion of the tube of FIG. 5;
FIG. 8 is a partially schematic view showing the tube of FIG. 5 during the bending process;
FIG. 9 is a partially schematic view showing the tube of FIG. 5 during a second step of the bending process; and
FIG. 10 is a partially fragmentary enlarged view of a portion of the tubular cabinet structure of FIG. 9.
DETAILED DESCRIPTION
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1. However, it is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.
With reference to FIG. 1, a refrigerator 1 includes an insulated cabinet structure 2 including generally upright side walls 4A and 4B, a horizontally extending upper side wall 6, and a generally horizontal lower side wall 8. Doors 10A and 10B are moveably connected to the insulated cabinet structure 2 to provide access to an insulated interior space 14 (see also FIG. 2) of the refrigerator 1. The refrigerator 1 is generally configured to be supported free-standing on a floor surface 12.
With further reference to FIG. 2, the insulated cabinet structure 2 includes a tubular primary structure 16 forming upright side walls 4A and 4B, upper side wall 6, and lower side wall 8. The tubular primary structure 16 is generally O-shaped, with a rectangular outer perimeter 18, and a rectangular inner perimeter 20. The inner perimeter 20 defines an enlarged rectangular front opening 22 and a rectangular rear opening 24. When assembled, the rear opening 24 is closed off by a rear wall assembly 26. The rear wall assembly 26 includes an upright panel 28, and a mullion cooling system 30. The rear wall assembly 26 may optionally include an insulated vertical panel or divider 32 that divides the insulated interior space 14 into a first space 14A and a second space 14B. The first space 14A may comprise a freezer space, and the space 14B may comprise a fresh food compartment. The mullion cooling system 30 may include an interior volume (not specifically shown in FIG. 2) that is configured to receive mechanical equipment for operating the various functions of the refrigerator 1. For example, a cooling module set can be disposed within the interior volume of the mullion 30. Examples of various cooling modules are disclosed in U.S. patent application Ser. No. 13/108,226 entitled “COOLING SYSTEM INTEGRATION ENABLED PLATFORM ARCHITECTURE” filed on May 15, 2011; U.S. patent application Ser. No. 13/108,293 entitled “FLEXIBLE COOLING SYSTEM INTEGRATION FOR MULTIPLE PLATFORMS” filed on May 16, 2011; and U.S. patent application Ser. No. 13/108,183 entitled “UNIVERSAL AND FLEXIBLE COOLING MODULE SET (CMS) CONFIGURATION AND ARCHITECTURE” filed on May 16, 2011. Each of these applications is hereby incorporated herein by reference in their entirety.
The tubular primary structure 16 is made from an elongated tube 44 (FIG. 5) that includes generally planar side walls 34 and 36 (FIG. 3), and edge or end walls 30 and 40 extending transversely between the inner and outer walls 36. As discussed in more detail below, the tubular primary structure 16 (FIG. 2) is made from a single elongated tube 44 that is deformed to form upper corners 46A and 46B, and lower corners 48A and 48B. Ends 50A and 50B of the tube are interconnected along an air-tight seam 52 that is preferably located in lower side wall 8. The tubular primary structure 16 includes a continuous, sealed insulating space 42 that is preferably filled with a porous filler material 54. The filler material 54 may comprise a silica powder such as fumed silica or other suitable material, and a vacuum may be formed in space 42 utilizing one or more inlet valves 56, and one or more outlet valves 58. Filler material 54 prevents collapse of tube 44 due to the vacuum formed in space 42 and provides superior insulation performance under vacuum.
With further reference to FIG. 4, tube 44 is initially formed utilizing an extrusion process. An extruding apparatus 60 extrudes the tube 44 in the direction of the arrow “A”. The extruding apparatus 60 may comprise a suitable known device. The tube 44 may be formed from a metal material such as low carbon steel, stainless steel, aluminum, or other suitable metal. Alternately, tube 44 may comprise a thermoplastic polymer material such as high impact polystyrene that is co-extruded with a layer of impermeable polymer material such as ethylene vinyl alcohol (EVOH). The EVOH layer is substantially impermeable to oxygen, nitrogen and water vapor to thereby enable formation and maintenance of a vacuum in internal space 42 when the tube 44 is formed into the tubular primary structure 16 (see also FIG. 2).
After a sufficient length of tubing 44 is extruded (FIG. 4), a cutting device or apparatus 62 having a cutter 64 is utilized to cut the elongated tube 44 along a plane 66 to thereby form a tube 44 (FIG. 5) having opposite ends 50A and 50B defining a length “L”. As discussed in more detail below, the tube 44 is bent along the fold lines 68A-68D to form corners 46A, 46B, 48A and 48B of the tubular primary structure 16 (FIG. 2). With further reference to FIG. 6, prior to formation of the corners 46A, 46B, 48A and 48B, the side walls 38 and 40 are first deformed inwardly at each fold line 68A-68D to form indentations 70 and 72. If tube 44 comprises a metal material, the indentations 70 and 72 may be formed utilizing dies or other known metal forming tools (not shown). If the tube 44 comprises a polymer material, the indentations 70 and 72 may be formed by first heating the elongated tube 44 to soften the polymer material, and a forming tool (not shown) may be utilized to push in the side walls 38 and 40 to form the indentations 70 and 72.
With further reference to FIG. 7, elongated grooves or indentations 74 and 76 (76 not anticipated but could be employed) may also be formed in one or both of side walls 34 and 36 at each fold line 68A-68D. The grooves 74 and 76 may be formed in addition to the indentations 70 and 72, or the grooves 74 and 76 may be formed in a tube 44 that does not include indentations 70 and 72. The grooves 74 and 76 include angled side walls 78A and 78B that intersect at a line or crease 80. The grooves 74 and/or 76 may be formed by heating the tube 44 if the tube 44 is formed of a polymer material, followed by pressing a forming tool (not shown) into the side wall 34 and/or 36 of tube 44. If tube 44 is made of a metal material, a conventional forming die or the like (not shown) may be utilized to form the grooves 74 and 76.
After formation of indentations 70 and/or 72 and grooves 74 and/or 76, the tube 44 is bent utilizing forming tools 82A-82D to form corners 46A, 46B, 48A and 48B as shown in FIGS. 8-9. The ends 50A and 50B are then joined together at seam 52. Seam 52 may comprise a welded joint or other suitable air-tight joint that is capable of maintaining a vacuum in the interior space 42 of the tubular primary structure 16. Prior to bending the tube as shown in FIGS. 8-9, the tube 44 may be filled with powdered silica such as fumed silica or other filler material. In general, the filler material 54 is inserted and compacted into the interior space 42 of tube 44 through one or both open ends 50A or 50B. Alternatively, as discussed below, the filler material 54 may be inserted into the interior space 42 utilizing valves/openings 56 and 58 (FIG. 2) after the tube 44 is deformed (FIGS. 8-9), and ends 50A and 50B are interconnected at seam 52.
With reference to FIG. 8, forming tools 82A and 82B are positioned along fold lines 68A and 68D, and a force is applied to the tube 44 adjacent to the end portions 50A and 50B to thereby fold the tube 44 as shown by the arrows “F1” and “F2”. Folding of the tube 44 forms end portions 84A and 84B, and corners 46A and 46B, respectively. Sand or other temporary filler material may be positioned inside tube 44 at fold lines 68A and 68D to assist in the bending process.
With further reference to FIG. 9, forming tools 82C and 82D are then positioned adjacent the forming lines or location 68B and 68C (FIG. 5), and a force is applied to a tube 44 to thereby deform the tube as shown by the arrows “F3” and “F4”. The ends 50A and 50B of tube 44 are then welded or otherwise secured together to form an air-tight seam 52.
As discussed above, the tubular primary structure 16 includes enlarged front and rear openings 22 and 24. The openings 22 and 24 generally define a rectangular perimeter 20, and the tubular primary structure 16 has a generally rectangular perimeter 18 in an elevational view (e.g. FIG. 9). The tubular primary structure 16 includes a generally rectangular “picture frame” front surface 86A and a rectangular rear surface 86B that is a mirror image of surface 86A. Referring again to FIG. 2, when assembled, the upright rear panel 28 is disposed adjacent or against rear surface 86A, and doors 10A and 10B are disposed against or adjacent surface 86A when the doors 10A and 10B are in the closed position.
With further reference to FIG. 10, after the tube 44 is deformed or folded to form corners 46A, 46B, 48A and 48B, the side walls of tube 44 generally deform as shown in FIG. 10 to form a crease 80 in inner wall 34 such that the surfaces 78A and 78B are directly adjacent one another, or in contact one another. In this way, the side walls 38 and 40 remain relatively flat in the region of the corners 46A, 46B, 38A and 38B. It will be understood that additional forming steps may be conducted in the vicinity of the corners to ensure that the outer surfaces of walls 38 and 40 are substantially planar.
Referring again to FIGS. 2 and 3, valves/ openings 56 and 58 can be utilized to remove air from cavity 42 to form a vacuum. As discussed above, the filler material 54 may be inserted and compacted into the space 42 of tube 44 prior to formation of seam 52. Alternately, the tube 44 may be formed as shown in FIGS. 4-9, and the filler material 54 may then be inserted into space 42 utilizing valves/ openings 56 and 58. If the filler material 54 is inserted into the space 42 prior to formation of seam 52, the primary structure 16 can be positioned in a vacuum chamber (not shown) after formation of seam 52, and one or both of the valves 56 and/or 58 can be opened to thereby form a vacuum in the inner space 42. The valves 56 and 58 can then be closed, and the tubular primary structure 16 can then be removed from the vacuum chamber. If the filler material 54 is inserted into the tube 44 prior to formation of seam 52, the filler material 54 is preferably compacted prior to the bending process shown in FIGS. 8 and 9. The filler material 54 may be inserted and compacted by closing off an end 50A (FIG. 5) of tube 44 utilizing a permeable barrier or filter (not shown) that permits airflow, but prevents flow of the filler material 54. The filler material 54 can then be blown into the open end 50B. Air can be circulated along the length of the tube 44 to thereby compact and distribute the filler material 54 throughout the interior space 42.
The filler material 54 may also be added after the tube 44 is bent into an O-shape (e.g. FIGS. 8 and 9) and after the seam 52 is formed. In this case, the valves or openings 56 and 58 can be utilized to fill the space 42 with the filler material 54. For example, a permeable barrier or filter may be positioned over opening 58, and filler material 54 may be blown into the space 42 utilizing valve or opening 56. As the filler material 54 is blown into the interior space 42, the airflow through the space 42 compacts the filler material. The tubular structure 16 may then be placed in a vacuum chamber, and the valves or openings 56 and/or 58 may be utilized to form a vacuum in the space 42 as discussed above. In general, the filler material 54 may comprise silica powder such as fumed silica or other porous material. The filler material 54 counteracts the inward forces acting on tube 44 due to the vacuum in space 42 and thereby prevents collapse or deformation of the side walls 34, 36, 38 and 40 of tubular structure 16.

Claims (19)

The invention claimed is:
1. A method of fabricating a vacuum insulated refrigerator housing, the method comprising:
forming an elongated tube having opposite open ends defining a length therebetween, the elongated tube having a substantially uniform cross sectional shape along the length of the tube, wherein the elongated tube defines generally planar first and second oppositely-facing primary outer surfaces and first and second end surfaces extending between the first and second primary outer surfaces;
deforming the tube along at least four fold lines to form at least four corners whereby portions of the first primary surface adjacent each corner are substantially orthogonal relative to one another;
connecting the opposite ends of the tube to one another forming an airtight and continuous insulating space within the tube to form a refrigerator housing structure having horizontally spaced apart generally vertical side walls and vertically spaced apart generally vertical upper and lower side walls, wherein the refrigerator housing structure defines an internal space with vertically enlarged front and rear openings;
forming a vacuum in the insulating space within the tube;
attaching an insulated rear panel to the refrigerator housing structure to at least partially close off the enlarged rear opening.
2. The method of claim 1, including:
attaching at least one movable door to the refrigerator housing structure, whereby the movable door can be shifted between a closed position that restricts access to the internal space, and an open position permitting access to at least a portion of the internal space.
3. The method of claim 1, wherein:
the tube is formed utilizing an extrusion process.
4. The method of claim 3, wherein:
the tube comprises a metal material.
5. The method of claim 3, wherein:
the tube comprises an impermeable polymer material.
6. The method of claim 5, wherein:
the impermeable polymer material comprises first and second layers of polymer material that are formed by extruding.
7. The method of claim 6, wherein:
the first layer comprises a substantially impermeable polymer material.
8. The method of claim 7, wherein:
the first and second layers define substantially uniform first and second thicknesses, respectively, wherein the first thickness is much less than the second thickness.
9. The method of claim 1, wherein:
the opposite ends of the tube are welded together to form a seam.
10. The method of claim 1, including:
filling the insulating space with a porous filler material.
11. The method of claim 10, including:
compacting the porous filler material prior to forming a vacuum in the insulating space.
12. The method of claim 11, wherein:
the porous filler material comprises fumed silica powder.
13. The method of claim 1, wherein:
the tube is placed in a vacuum chamber prior to sealing the opposite ends of the tube.
14. The method of claim 1, including:
forming an indentation in at least one of the primary outer surfaces or the end surfaces at each of the fold lines prior to forming the four corners.
15. A method of forming a vacuum insulated refrigerator housing, the method comprising:
providing an elongated tube having opposite and open ends;
positioning the opposite ends of the tube adjacent one another by deforming the tube;
connecting the opposite ends together to form an airtight and continuous insulating space within the tube, and having spaced apart upright side walls and spaced apart upper and lower side walls extending between the upright side walls, wherein the refrigerator housing structure defines an internal space and enlarged front and rear openings,
forming a vacuum in the airtight insulating space, and
attaching an insulated rear panel to the refrigerator housing structure to at least partially close off the enlarged rear opening.
16. The method of claim 15, wherein:
forming the tube includes simultaneously extruding first and second polymer materials to form first and second layers.
17. The method of claim 16, wherein:
the first polymer material comprises EVOH.
18. The method of claim 15, including:
filling the tube with a porous filler material prior to forming a vacuum in the airtight insulating space.
19. The method of claim 15, including:
positioning the tube in a vacuum chamber prior to sealing off the opposite ends.
US13/836,143 2012-04-02 2013-03-15 Vacuum insulated structure tubular cabinet construction Expired - Fee Related US9071907B2 (en)

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US13/837,659 US8986483B2 (en) 2012-04-02 2013-03-15 Method of making a folded vacuum insulated structure
US13/836,143 US9071907B2 (en) 2012-04-02 2013-03-15 Vacuum insulated structure tubular cabinet construction
US13/833,696 US9038403B2 (en) 2012-04-02 2013-03-15 Vacuum insulated door structure and method for the creation thereof
US13/836,669 US9140481B2 (en) 2012-04-02 2013-03-15 Folded vacuum insulated structure
US13/835,449 US8944541B2 (en) 2012-04-02 2013-03-15 Vacuum panel cabinet structure for a refrigerator
US13/832,246 US9182158B2 (en) 2013-03-15 2013-03-15 Dual cooling systems to minimize off-cycle migration loss in refrigerators with a vacuum insulated structure
EP14158608.1A EP2778580B1 (en) 2013-03-15 2014-03-10 Vacuum insulated structure tubular cabinet construction
BR102014005924-5A BR102014005924B1 (en) 2013-03-15 2014-03-13 method for making a vacuum insulated cooler housing and method for forming a vacuum insulated cooler housing
US14/635,313 US9874394B2 (en) 2012-04-02 2015-03-02 Method of making a folded vacuum insulated structure
US14/635,109 US9885516B2 (en) 2012-04-02 2015-03-02 Vacuum insulated door structure and method for the creation thereof
US14/731,796 US9835369B2 (en) 2012-04-02 2015-06-05 Vacuum insulated structure tubular cabinet construction
US15/794,785 US10663217B2 (en) 2012-04-02 2017-10-26 Vacuum insulated structure tubular cabinet construction

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US201261618914P 2012-04-02 2012-04-02
US13/837,659 US8986483B2 (en) 2012-04-02 2013-03-15 Method of making a folded vacuum insulated structure
US13/836,143 US9071907B2 (en) 2012-04-02 2013-03-15 Vacuum insulated structure tubular cabinet construction
US13/833,696 US9038403B2 (en) 2012-04-02 2013-03-15 Vacuum insulated door structure and method for the creation thereof
US13/833,635 US20130257257A1 (en) 2012-04-02 2013-03-15 Method to create vacuum insulated cabinets for refrigerators
US13/836,669 US9140481B2 (en) 2012-04-02 2013-03-15 Folded vacuum insulated structure
US13/835,449 US8944541B2 (en) 2012-04-02 2013-03-15 Vacuum panel cabinet structure for a refrigerator
US13/832,246 US9182158B2 (en) 2013-03-15 2013-03-15 Dual cooling systems to minimize off-cycle migration loss in refrigerators with a vacuum insulated structure
US13/833,685 US9221210B2 (en) 2012-04-11 2013-03-15 Method to create vacuum insulated cabinets for refrigerators

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US9071907B2 true US9071907B2 (en) 2015-06-30

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US13/836,669 Active 2034-01-03 US9140481B2 (en) 2012-04-02 2013-03-15 Folded vacuum insulated structure
US13/836,143 Expired - Fee Related US9071907B2 (en) 2012-04-02 2013-03-15 Vacuum insulated structure tubular cabinet construction
US13/833,696 Active 2033-10-19 US9038403B2 (en) 2012-04-02 2013-03-15 Vacuum insulated door structure and method for the creation thereof
US13/835,449 Active 2033-07-12 US8944541B2 (en) 2012-04-02 2013-03-15 Vacuum panel cabinet structure for a refrigerator
US13/837,659 Active US8986483B2 (en) 2012-04-02 2013-03-15 Method of making a folded vacuum insulated structure
US14/635,109 Active 2033-10-05 US9885516B2 (en) 2012-04-02 2015-03-02 Vacuum insulated door structure and method for the creation thereof
US14/635,313 Active 2033-08-23 US9874394B2 (en) 2012-04-02 2015-03-02 Method of making a folded vacuum insulated structure
US14/731,796 Active 2033-11-03 US9835369B2 (en) 2012-04-02 2015-06-05 Vacuum insulated structure tubular cabinet construction
US15/794,785 Expired - Fee Related US10663217B2 (en) 2012-04-02 2017-10-26 Vacuum insulated structure tubular cabinet construction
US15/797,217 Active 2033-09-09 US10746458B2 (en) 2012-04-02 2017-10-30 Method of making a folded vacuum insulated structure
US15/842,176 Active 2033-10-26 US10697697B2 (en) 2012-04-02 2017-12-14 Vacuum insulated door structure and method for the creation thereof
US16/927,079 Active 2033-10-25 US11549744B2 (en) 2012-04-02 2020-07-13 Method of making a folded insulated structure

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US13/833,696 Active 2033-10-19 US9038403B2 (en) 2012-04-02 2013-03-15 Vacuum insulated door structure and method for the creation thereof
US13/835,449 Active 2033-07-12 US8944541B2 (en) 2012-04-02 2013-03-15 Vacuum panel cabinet structure for a refrigerator
US13/837,659 Active US8986483B2 (en) 2012-04-02 2013-03-15 Method of making a folded vacuum insulated structure
US14/635,109 Active 2033-10-05 US9885516B2 (en) 2012-04-02 2015-03-02 Vacuum insulated door structure and method for the creation thereof
US14/635,313 Active 2033-08-23 US9874394B2 (en) 2012-04-02 2015-03-02 Method of making a folded vacuum insulated structure
US14/731,796 Active 2033-11-03 US9835369B2 (en) 2012-04-02 2015-06-05 Vacuum insulated structure tubular cabinet construction
US15/794,785 Expired - Fee Related US10663217B2 (en) 2012-04-02 2017-10-26 Vacuum insulated structure tubular cabinet construction
US15/797,217 Active 2033-09-09 US10746458B2 (en) 2012-04-02 2017-10-30 Method of making a folded vacuum insulated structure
US15/842,176 Active 2033-10-26 US10697697B2 (en) 2012-04-02 2017-12-14 Vacuum insulated door structure and method for the creation thereof
US16/927,079 Active 2033-10-25 US11549744B2 (en) 2012-04-02 2020-07-13 Method of making a folded insulated structure

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US10746458B2 (en) 2020-08-18
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US20150168050A1 (en) 2015-06-18
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US10697697B2 (en) 2020-06-30
US20180045455A1 (en) 2018-02-15
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US20130256318A1 (en) 2013-10-03
US20180106529A1 (en) 2018-04-19
US8944541B2 (en) 2015-02-03
US20130256319A1 (en) 2013-10-03
US9835369B2 (en) 2017-12-05
US9874394B2 (en) 2018-01-23
US20200340735A1 (en) 2020-10-29
US9885516B2 (en) 2018-02-06
US9038403B2 (en) 2015-05-26
US8986483B2 (en) 2015-03-24
US10663217B2 (en) 2020-05-26
BR102014005701A2 (en) 2015-05-05
US20180045456A1 (en) 2018-02-15
US20130305535A1 (en) 2013-11-21
US20130257256A1 (en) 2013-10-03
US20130255304A1 (en) 2013-10-03

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